Search Results (1,000)

Polyester resin biocomposites containing biochar have attracted attention for improving mechanical strength and thermal stability while promoting sustainability. The pyrolysis temperature of biochar and its proportion in the polymer matrix are key factors affecting biocomposite performance. This study examined how biochar pyrolysis temperatures (400, 600, 800 °C) and incorporation levels (10, 20, 30 wt.%) influence the physical, chemical, mechanical, flammability, and morphological properties of polyester-based biocomposites. The samples were analyzed for density, water absorption, FTIR, XRD, flexural and tensile strength, ignition time, structural degradation, volumetric loss, and SEM microstructure. Biocomposites with 30 wt.% biochar produced at 800 °C showed the best mechanical properties, with a flexural strength of 95.3 MPa and an elastic modulus of 4417.4 MPa, representing increases of 14.5% and 45.7%, respectively, over the control. FTIR and XRD results revealed decreased aliphatic groups and increased aromaticity at higher pyrolysis temperatures, improving interactions between the matrix and biochar. These biocomposites also demonstrated enhanced thermal stability, with an ignition time of approximately 963 s, delayed structural degradation, and reduced volumetric loss (~19.3%). Overall, pyrolysis temperature and biochar content significantly influence the structural, mechanical, and thermal properties of polyester biocomposites, showing that biochar serves as a sustainable, performance-enhancing component in thermoset polymer matrices. Full article

In ultra-high-voltage GIS and GIL systems, epoxy resin insulators are still the mainstream choice. However, as a thermosetting material, epoxy resin is difficult to recycle after disposal, which limits its environmental benefits. Thermoplastic insulators, due to their recyclability, are potential alternatives. This study focuses on 30% glass fiber-reinforced PET and PA6 materials. Their injection molding behavior, hydraulic pressure performance, and insulation performance were systematically analyzed using Moldflow, ANSYS, and COMSOL, respectively. For injection molding, Moldflow simulations were conducted for filling, packing, and cooling stages. Melt temperature was varied from 260 to –310 °C (PET) and 250–300 °C (PA6), while mold temperature was varied from 80 to –130 °C (PET) and 70–120 °C (PA6). An optimization objective function, Y = Δp/20 + Δx/0.5 + Δs/1.8, was developed to determine optimal processing parameters. Based on this function, the optimal parameters identified are: PET at 290 °C melt temperature and 120 °C mold temperature; PA6 at 250 °C melt temperature and 70 °C mold temperature. For hydraulic testing, Moldflow–ANSYS coupled simulations were performed under 2.4 MPa pressure with the compliance criteria of bulk stress < 90 MPa and insert-contact stress < 20 MPa. PA6 passed within a processing window of melt temperature < 270 °C and mold temperature < 120 °C. PET failed under all tested conditions, with insert-contact stress ranging from 24.25 to 27.55 MPa, consistently exceeding the 20 MPa threshold. In terms of insulation performance, this paper utilizes COMSOL to study the electric field distribution of thermoplastic insulators in SF₆ GIS/GIL and provides optimization suggestions for insulator geometry design. This study systematically compares the injection molding processes and hydraulic pressure performance of PET and PA6 thermoplastic insulators. These results provide important process insights and design guidance for evaluating thermoplastic materials as potential alternatives to epoxy resin in GIS/GIL applications. Full article

Sustainable structural composites can significantly lower vehicle-related emissions. To evaluate the recycling of different composite materials, laboratory-scale pyrolysis was conducted and assessed both technically and environmentally. Two demonstrators were studied: a truck side skirt made from natural flax and hemp fibres with polypropylene (PP), and a car front header composed of glass fibres and PP. Additional materials examined included thermoplastic composites containing polyamide 6 (PA6), bio-based polyamide 11 (PA11) and thermoset polyester. Results showed that material type strongly influenced the pyrolysis outcome, product composition and recycling potential. Glass fibres could be recovered and reused as reinforced fibres, while natural fibres could be recovered as biooil for potential use in biofuel production. Polymers were recovered as pyrolysis products that, depending on their composition, can be used in different applications, from recovering monomers from PA6 to producing hydrocarbons that may replace naphtha (from PP) or aromatics (from polyester) in the petrochemical industry. Life cycle assessment (LCA) findings revealed that the climate impact of composite recycling is primarily driven by the environmental burdens of the recycling process itself and by the ability of recovered materials and chemicals to substitute conventional fossil-based alternatives. Efficient recycling pathways are therefore essential to maximising environmental benefits. Full article

In liquid composite moulding processes, the curing behaviour of thermoset matrices plays a decisive role in determining manufacturing quality and cycle time. Premature demoulding may lead to insufficiently cured components, whereas excessively long curing times reduce production efficiency. Reliable monitoring and modelling of the curing process are therefore essential for process optimisation. In this study, the cure kinetics of a fast-curing epoxy resin system are modelled using the Grindling kinetic model, which accounts for diffusion-controlled reaction behaviour and vitrification effects. Model parameters are identified using both dynamic and isothermal differential scanning calorimetry (DSC) measurements. In addition, the glass transition temperature is described as a function of the degree of cure using the DiBenedetto relationship. To demonstrate the applicability of the model for process monitoring, an experimental mould equipped with temperature sensors was developed to simulate real-time estimation of the degree of cure during isothermal processing. The predicted degree of cure is validated by post-process DSC analysis of the manufactured samples. Initial comparisons reveal systematic deviations caused by temperature measurement uncertainties. After implementing a temperature correction based on experimentally determined sensor deviations, the predicted degree of cure shows significantly improved agreement with DSC measurements. The results demonstrate that combining kinetic modelling with temperature monitoring enables reliable real-time estimation of the curing state for fast-curing epoxy systems. The study also highlights the critical importance of accurate temperature measurement for curing monitoring and provides insights into the practical implementation of sensor-based monitoring strategies in liquid composite moulding processes. Full article

Photopolymer-based additive manufacturing processes such as stereolithography (SLA) offer high precision and surface quality but generate cured thermoset waste that is typically non-recyclable. In microgravity environments, conventional recycling approaches—based on gravitational settling, open solvent handling, and buoyancy-driven degassing—are ineffective, motivating the development of fully contained, gravity-independent material recovery systems for on-orbit manufacturing. This work presents a conceptual, design-stage closed-loop system architecture for recycling photopolymer resins in microgravity. The system integrates eight subassemblies enabling mechanical fragmentation, solvent-assisted dissolution, filtration, low-pressure degassing, pressurized storage, injection molding, and ultraviolet curing. A hermetically sealed dual-screw shredder produces resin fragments of 1–3 mm, suitable for dissolution. Gas removal is achieved through low-vacuum degassing at approximately 0.1–0.3 bar, with characteristic residence times of 5–10 min, ensuring stable processing prior to injection. Material transport is governed by mechanical conveyance and controlled pressure, eliminating reliance on gravity. The architecture maintains full containment of solids, liquids, and vapors throughout the process. Supported by engineering design considerations, the system establishes a microgravity-compatible pathway for closed-loop recycling of SLA materials. Experimental validation is planned in future work. Full article

Epoxy resins (EP) are widely used in aerospace, electronics, and coatings due to their excellent mechanical and thermal properties. However, their inherent flammability and brittleness limit high-end applications. In this work, a novel reactive flame retardant epoxy monomer (EP-DVGA) containing DOPO and triazole units was designed and synthesized via a molecular engineering strategy. The chemical structure was confirmed by FTIR and NMR. A series of modified epoxy thermosets were prepared by co-curing EP-DVGA with bisphenol A epoxy resin (E51) using DDM as curing agent. The results showed that EP-DVGA significantly enhanced flame retardancy: At 16.31 wt% loading, the limiting oxygen index increased from 25.9% to 34.3% with UL-94 V-0 rating, and cone calorimetry revealed 73.2% and 69.2% reductions in peak heat release rate and total heat release, respectively. Mechanistic studies demonstrated a dual flame retardant effect involving phosphorus radical quenching in the gas phase and formation of a dense graphitized char layer in the condensed phase. Remarkably, EP-DVGA also improved mechanical properties—impact strength increased by 47% and tensile strength by 33.1% at optimal loadings—attributed to energy dissipation through reversible hydrogen bonding and π–π interactions. This molecular design successfully overcomes the traditional trade-off between flame retardancy and mechanical performance, offering a promising strategy for developing high-performance intrinsically flame retardant epoxy materials. Full article

In the present study, the influence of the parameters of the bonding process, namely the applied pressure during curing, as well as the duration and temperature of curing, on the tensile strength of the bonded joints was investigated. Pull-off tests were conducted in accordance with the ASTM C633 standard. The samples were bonded using a single-component thermosetting adhesive, HTK Ultra Bond 100. On the basis of the results obtained, it was concluded that the tensile strength of the bonded joint, and thus its overall quality, is strongly influenced by the curing parameters of the thermosetting adhesive. The most effective bonding conditions were identified. Full article

Epoxy materials are an important class of thermosets whose properties strongly depend on the used formula, the curing parameters, and many available hardeners. Achieving desired properties such as enhanced thermal stability, extended lifetime, or self-regeneration requires selecting suitable precursors and carefully tuning curing conditions. In this work, a selected biphenyl epoxy precursor was used as a model compound to assess whether using different hardeners could be an effective factor in tailoring the elasticity of cured epoxy networks. We employed two chemically distinct hardeners—4,4′ diaminodiphenylmethane (DDM) and suberic acid—to generate materials with markedly different final properties. For instance, the glass transition temperature T_g varied within a range of over 35 °C. Two complementary experimental techniques were used in this paper to establish the optimal curing parameters: differential scanning calorimetry (DSC) and broadband dielectric spectroscopy (BDS). Both techniques supported tracking of changes in the mixture while curing and enabled determination of T_g in the obtained products. Dielectric relaxation spectroscopy revealed various molecular motions (α, β, and γ-processes) occurring in different phases, especially in glass-forming solids. BDS is therefore a good tool for testing new organic materials. The analytic route used in this work, based on a combination of calorimetric and electrical approaches, enables precise adjustment of the curing parameters to a specific hardener and helps verify the effects of using different hardeners on the elastic properties of the product. This allows the creation and modification of epoxy matrices towards modern materials, such as composites with self-healing properties or enhanced thermal stability. Full article

The growing volume of fiber-reinforced polymer composite waste creates an urgent need for efficient recycling technologies. While solvolysis effectively breaks down thermoset matrices for fiber reinforcement recovery, the process generates hydrocarbon-rich liquid by-products that require further management. This study validates the use of these liquid recycling streams—derived from the solvolysis of unsaturated polyester and epoxy resins—as sustainable carbon precursors for the growth of carbon nanomaterials. Synthesis was performed via catalytic chemical vapor deposition (CVD) at 850 °C using iron nanoparticles impregnated on a zeolite substrate. Morphological analysis confirmed the production of one-dimensional nanostructures (carbon nanotubes/nanofibers), with average diameters below 100 nm. Raman spectroscopy revealed a high degree of graphitization, with I_D/I_G ratios ranging from 0.25 to 0.58, which is comparable to structures synthesized from conventional precursors. Thermogravimetric analysis (TGA) demonstrated high thermal stability and carbon purity reaching up to 90.3%. These findings demonstrate a viable upcycling pathway that enhances the economic attractiveness of composite recycling by transforming waste into advanced nanomaterials. Full article

Conventional phenolic-resin-based carbon fiber paper (CFP) typically suffers from low mechanical strength, poor toughness, insufficient pore interconnectivity, and a reliance on extreme high-temperature graphitization to attain high conductivity. This study employs a novel melamine-hexamethylenediamine (MH) thermosetting resin as the binder to fabricate MH resin-based CFP (MHCFP). Through the synergistic effects of robust interfacial bonding, triazine-ring-induced low-temperature formation of sp² carbon clusters, and nitrogen doping, the MHCFP achieves comprehensive performance superiority over the phenol-formaldehyde (PF)-based CFP (PFCFP) at moderate carbonization temperatures (500–700 °C): MHCFP exhibits superior toughness, tensile strengths of 23–45 MPa (vs. PFCFP’s 8–18 MPa), and in-plane resistivity of 24–39 mΩ·cm (vs. PFCFP’s 54–83 mΩ·cm). Furthermore, MHCFP possesses a highly open macroporous structure (porosity > 78%), ensuring excellent gas permeability and water management capability. This work presents a promising low-temperature strategy for developing high-performance CFP, showing great potential for next-generation proton exchange membrane fuel cell gas diffusion layers. Full article

Unsaturated polyester resin (UPR)–quartz composites have become increasingly important in structural, sanitary, and architectural applications. However, their manufacturing processes still rely heavily on empirical knowledge. This review compiles recent developments in materials science, curing kinetics, and digital manufacturing, outlining a pathway toward data-driven, adaptive production of quartz-filled thermosets. The chemical and physical fundamentals of UPR polymerization are summarized, including the influence of initiator systems, filler characteristics, and thermal management on network formation. Challenges associated with highly filled formulations—such as viscosity control, dispersion, shrinkage, and exothermic peak prediction—are discussed in detail. Recent advances in digital twins (DTs) and artificial intelligence (AI) are reviewed, demonstrating how physics-based simulations, machine learning models, and hybrid mechanistic–data-driven approaches improve the prediction of rheology, curing behavior, and quality outcomes in thermoset polymer processes. A practical application example demonstrates the prediction of peak time in quartz–UPR composites using Random Forest and Gradient Boosting ensemble models. Two prediction scenarios are evaluated: Scenario A with gel time by Leave-One-Out cross-validation, and Scenario B without gel time, representing post-mixing and pre-process prediction contexts, respectively. Stratified bootstrap augmentation improves Gradient Boosting in both scenarios. Principal component analysis confirms that the curing process is governed by three independent physical dimensions: curing reactivity, thermal environment and resin thermal state. Full article

In the transition toward the circular economy and high-rate manufacturing, thermoplastic composites (TPCs) are increasingly outperforming conventional thermosets due to their superior fracture toughness, recyclability, and rapid processing capabilities. Among available joining techniques, fusion bonding stands as the main mechanism for structural integration, as it bypasses the fundamental limitations of traditional assembly: the weight penalties and stress concentrations inherent in mechanical fastening, as well as the long cycle times and interfacial weaknesses often associated with adhesive bonding. This paper provides a comprehensive evaluation of welded TPC joints through a dual-methodological approach: a historical narrative review tracing the evolution of fusion bonding principles, and an in-depth literature review of 25 key articles published since 2015. The analysis focuses on the intersection of experimental characterization—quantifying interfacial strength and fracture energy—and numerical modeling techniques, such as Cohesive Zone Modeling (CZM) and progressive damage analysis. By categorizing recent advancements into specific thematic pillars, this study correlates process-induced phenomena with macro-scale mechanical performance and virtual predictive accuracy. The findings synthesize decades of foundational knowledge with cutting-edge research trends, highlighting the transition from empirical testing to computational design. This work serves as a roadmap for achieving standardized, high-performance thermoplastic assemblies in safety-critical applications. Full article

Tourmaline nanoparticle-reinforced DGEBA/MTHPA epoxy nanocomposites were developed to obtain mechanically robust insulating materials with reduced dielectric loss. Composites containing 0–20 phr tourmaline were prepared by mechanical mixing, vacuum degassing, and stepwise curing, and FTIR verified successful curing and network formation. Tourmaline delivered stiffness-dominated reinforcement, increasing the flexural modulus from 2.585 to 4.07 GPa. At 5 phr, the composites reached simultaneous maxima in flexural strength and impact strength, corresponding to improvements of 5.02% and 57.4% over the unfilled resin, respectively. Moreover, the modified epoxy thermosets still maintained excellent T_g and thermal decomposition temperature. Electrical insulation improved concurrently, as volume resistivity increased from 1.36 × 10¹⁶ Ω·cm for EP-0 to 1.89 × 10¹⁶ Ω·cm for EP-20, and surface resistivity rose from 1.72 × 10¹⁵ to 2.49 × 10¹⁵ Ω, giving 9.6–39.0% and 14.2–44.9% gains for EP-5 to EP-20. Notably, at 50 Hz, 5 phr tourmaline preserved a low permittivity of 4.360 while reducing dielectric loss tangent (tan δ) from 0.0270 to 0.0190, a 29.6% decrease. Collectively, these improvements reduce dielectric heating and support reliable operation of epoxy-based insulation in power equipment. Full article

The transition to sustainable thermosetting resins is frequently hindered by the trade-off between high bio-based content and processability. This study reports a novel strategy in developing a highly bio-based, styrene-free unsaturated polyester resin (UPR) by leveraging maltodextrin-derived mixed esters dissolved in dimethyl itaconate (DMI). Unlike conventional polysaccharide-based systems that suffer from extreme viscosity, our functionalized prepolymer–DMI system achieves a low-viscosity curing solution without requiring petroleum-derived diluents such as styrene. Fourier-transform infrared spectroscopy confirmed the formation of a robust crosslinked network via the complete consumption of C=C bonds. Consequently, the cured resin exhibits exceptional thermal and mechanical performance, outperforming many existing bio-based analogs: a glass transition temperature (T_g) reaching 141 °C, a decomposition onset near 250 °C, and superior dimensional stability with a linear thermal expansion coefficient as low as 77 ppm/°C. Demonstrating a fully renewable, easy-to-process formulation with a flexural strength of 44 MPa, this work provides a design template for the next generation of high-performance, eco-friendly industrial thermosets. Full article

Thermosetting polyurethane (PU) has recently been introduced as an asphalt modifier to improve the mechanical strength and durability of pavements. However, the permanent crosslinked network of thermosetting PU makes the material difficult to repair once damage accumulates. In contrast, self-healing asphalt technologies rely on either extrinsic healing agents or intrinsic dynamic bonds to restore stiffness and delay cracking. Dynamic disulfide bonds are a promising class of reversible covalent bonds that can rearrange at moderate temperatures and have been widely used to build self-healing polyurethane networks. This study investigates a disulfide-crosslinked polyurethane-modified asphalt binder (DP10) and compares its fatigue and healing performance with base asphalt (BA), thermosetting PU-modified asphalt (P10), and styrene–butadiene–styrene (SBS)-modified asphalts (S3 and S10). A dynamic shear rheometer (DSR) was used to conduct time sweep fatigue tests, linear amplitude sweep (LAS) tests, and fatigue–healing–fatigue protocols. Fourier transform infrared spectroscopy (FTIR) was employed to confirm the formation of polyurethane and disulfide structures. Results show that DP10 significantly increases fatigue life at small to medium strain levels compared with BA and P10 and performs competitively with SBS-modified binders. More importantly, DP10 exhibits a much higher healing index than P10 and maintains strong healing capability over repeated fatigue–healing cycles, approaching the intrinsic healing level of base asphalt. These findings demonstrate that incorporating dynamic disulfide bonds into thermosetting PU networks provides a practical route to binders that combine high strength with recoverability, which is attractive for long-life, self-healing pavement design. Full article